Selective hydrogenation catalyst

ABSTRACT

A catalyst and process for the selective hydrogenation of acetylene, said catalyst comprising palladium and silver with the palladium concentrated as a skin and the silver distributed throughout.

This invention relates to a new catalyst for the selective hydrogenationof acetylene as well as a method for making such catalyst and to amethod for the selective hydrogenation of acetylene in admixture withethylene.

Ethylene is a monomer that is used in preparing a number of olefinpolymers. Ethylene is generally made by the pyrolysis or catalyticcracking of refinery gas, ethane, propane, butane, and the like.Ethylene so produced usually contains small proportions of acetylene. Inpolymer grade ethylene, it is generally preferred that the acetylenecontent be less than about 10 ppm, most preferably less than about 5ppm.

One of the techniques that has been used in the past for reducing theamount of acetylene in an ethylene stream has involved selectivehydrogenation using a catalyst comprising palladium supported on anactivated alumina carrier. Numerous factors have been found to affectthe selectivity of such palladium catalysts.

Typically, as the temperature is increased above that which givessubstantial elimination of acetylene, there is a progressive increase inthe amount of ethylene and acetylene that is converted to ethane. As theamount of olefin that is hydrogenated increases typically, thetemperature of the catalyst also increases resulting in runaway ethylenehydrogenation. Since ethylene is the desired product and since sometemperature fluctuations are to be expected in commercial scaleoperations, it is obviously desirable to be able to operate withcatalyst and conditions that will allow a relatively wide spread betweenthe temperature which produces the substantial elimination of acetyleneand the temperature that cause levels of ethane production that areintolerable. Generally, it is desirable to use a catalyst with whichthere is at least about a 30° F. temperature difference betweensubstantially complete acetylene removal and incipient runaway.

It has recently been discovered that a particularly active catalyst forselective acetylene hydrogenation results when the palladium isconcentrated near the surface of the alpha alumina particles. Such"skin" catalysts are less sensitive to the effects of the carbonmonoxide concentration in the feed than catalysts in which the palladiumis more widely distributed in the catalyst particles. However, when such"skin" catalysts are employed on feedstreams containing less than 600ppm carbon monoxide, it has been noted that the temperature rangebetween substantially complete acetylene removal and runaway ethylenehydrogenation is not as broad as would be desired. This temperaturerange decreases as the carbon monoxide content of the feedstream isreduced. When such "skin" catalysts are employed on hydrocarbon streamscontaining levels of CO lower than about 600 ppm runaway olefinhydrogenation can even occur before there has been substantiallycomplete acetylene hydrogenation.

It is well recognized that the amount of carbon monoxide in the effluentfrom an ethane cracker can vary over a large range depending on theoperating conditions, the character of the feed to the cracker, and thelike. Accordingly, it is desirable to find a way to make the "skin" typepalladium catalysts less sensitive to variations in the carbon monoxidecontent of the ethylene-containing feedstream.

An object of this invention is to provide a method, and catalysts, forthe treatment of gas mixtures comprising ethylene and acetylene wherebythe acetylene is selectively and substantially consumed.

A further object is to provide such a method and catalyst wherebyacetylene in admixture with ethylene is hydrogenated to form a furtheramount of ethylene, without the concurrent consumption of a significantproportion of ethylene.

Another object is to provide such a method and catalysts whereby theoperations can be continued for a prolonged time on a large scalewithout occurrence of a dishabilitating proportion of side reactionssuch as carbonization and polymerization.

Still another object of the present invention is to reduce the extent towhich palladium "skin" type catalysts are affected by the carbonmonoxide content of the hydrogenation feed.

FIG. 1 is a graph illustrating the advantages of the present invention.

The novel hydrogenation catalyst of the present invention comprisesparticles of alpha alumina containing palladium and silver. Thepalladium is about 0.01 to about 0.025 weight percent of the catalyst.The weight percent silver is at least twice that of the palladium. Theinventive catalyst is further characterized in that at least 90 weightpercent of the particles of alpha alumina have the palladiumconcentrated in an area within 300 microns of the exterior surface whilethe silver is distributed throughout the particles. For reasons ofeconomics, the amount of silver in the catalyst is generally not morethan about 10 times that of the palladium, preferably it is in the rangeof about 2 to about 6 times that of the palladium.

Any suitable alumina can be employed which will result in a cataysthaving an alpha alumina support. Typical alpha aluminas have surfaceareas in the range of about 3 to about 7 square meters per gram, porevolume of about 0.24 to about 0.34 cubic centimeters per gram, and amean pore radius in the range of about 685 to about 2270 Angstrom units.

These characteristics of the alpha alumina can be determined using thefollowing methods on samples of the alumina that has been degassed atroom temperature for 30 minutes at a pressure of 10⁻³ mm or less:

(1) The surface area is found by the well-known method of Brunauer,Emmett, and Teller by measuring the quantity of argon adsorbed on thecatalyst at -183° C. with the cross-sectional area of the argon atombeing taken as 14.4 square Angstrom units.

(2) Determining the pore volume involves determining the "mercurydensity" and the "helium density". The mercury density is determined byimmersing the support in mercury at 20° C. and 900 mm pressure, underwhich conditions about 15 minutes are allowed for attainment ofequilibrium. The helium density is determined by immersing the supportin helium at room temperature. The pore volume per gram is found bysubtracting the reciprocal of the "helium density" from the reciprocalof the "mercury density."

(3) The mean pore radius is determined by the formula

    r=(2V/A)

where r is the mean pore radius, V is the pore volume, and A is thesurface area. If V is expressed in cubic centimeters and A is expressedin square centimeters, the mean radius r is in centimeters and should bemultiplied by 10⁸ to give the mean radius in Angstrom units.

The palladium can be placed on the alumina in any suitable manner thatwill yield a catalyst meeting the above-described parameters. Thepresently preferred technique involves impregnating the alumina with anaqueous solution of palladium chloride. The extent of penetration of thepalladium can be controlled by adjustment of the acidity of the solutionwith hydrochloric acid.

The catalyst particles can be of any suitable shape and dimensions,however, the advantages of the skin type catalyst are particularlynotable for those particles having minimum dimensions of at least about1 millimeter. A particularly suitable form of catalyst particle is onehaving dimensions in the range of about 2 to about 6 millimeters.

One can use any suitable method to determine whether at least 90 weightpercent of the catalyst particles have the palladium concentrated in anarea within 300 microns of the exterior surface. One technique currentlyfavored involves breaking open a representative sample of catalyst pillsand treating them with a dilute alcoholic solution ofN,N-dimethyl-para-nitrosoaniline. The treating solution reacts with thepalladium to give a red color which can be used to evaluate thedistribution of the palladium.

The silver can be distributed throughout the catalyst in any suitablemanner. It is currently preferred to employ an aqueous silver nitratesolution in a quantity greater than that necessary to fill the porevolume of the catalyst. Attempts to improve the sensitivity of thecatalyst by using incipient impregnation have not been successful, evenwhen solutions were used that should have provided a 5 to 1 weight ratioof silver to palladium. This is considered to result from imperfectcontacting which leaves significant amounts of catalyst particles withdeficient amounts of silver.

The impregnated catalyst is dried at a temperature in the range of about25° C. to about 150° C.

The dried catalyst can be employed directly as a catalyst forhydrogenation, however, preferably it is roasted to decompose thecompounds providing the palladium and silver. This roasting can be doneat temperatures up to about 500° C., temperatures in the range of 150°C. to 450° C. being preferred. The roasting is also preferably followedby a reduction step. This reduction can be accomplished using the feedfor the selective hydrogenation; however, it is preferable to reduce thecatalyst with a gas such as hydrogen since optimum operation of theselective hydrogenation does not begin until there has been reduction ofthe catalytic metals. Typically, the reduction is carried out at atemperature in the range of about 25° C. to about 450° C.

The selective hydrogenation is carried out by passing the gas stream ofethylene, containing the acetylene to be removed, along with hydrogeninto contact with the catalysts of the present invention. In order tobest approach substantially complete removal of the acetylene, thereshould be at least one mole of hydrogen for each mole of acetylene.

The temperature necessary for the selectivity hydrogenation dependslargely upon the activity of the catalyst and the extent of acetyleneremoval desired. Generally temperatures in the range of about 35° C. toabout 100° C. are used. Any suitable reaction pressure can be employed.Generally, the total pressure is in the range of about 100 to about1,000 pounds per square inch gauge. The gas hourly space velocity (GHSV)can also vary over a wide range. Typically, the space velocity will bein the range of about 1,000 to about 10,000 liters of feed per liter ofcatalyst per hour, more preferably about 2,000 to about 8,000.

Regeneration of the catalyst may be accomplished by heating the catalystin air at a temperature preferably not in excess of 500° C. to burn offany organic matter, polymer, or char.

The high loading of silver relative to the palladium in the presentcatalysts is also expected to make the catalysts less sensitive to beingpoisoned by arsenic that may be present in the feed.

A further understanding of the present invention and its advantages willbe provided by the following examples.

EXAMPLE I Catalyst Preparations

First, a skin-type catalyst was prepared by impregnating alpha aluminapills (3/16"×3/16") with an aqueous solution of palladium chlorideacidified with hydrochloric acid to produce a catalyst containing about0.017 weight percent palladium. Over 90 percent of the resultingcatalyst pills had the palladium deposited in the peripheral 300micrometers. This catalyst will be designated as Catalyst A.

Another catalyst was prepared by immersing at room temperature 36.3grams of Catalyst A in 20 milliliters of water having 0.057 grams ofsilver nitrate dissolved therein. The catalyst pills were stirred aroundin the solution for a few minutes, then the excess solution wasdecanted. Ten milliliters of the solution was recovered. The recoveredsolution was analyzed and the silver nitrate content was 0.0152 molarwhereas that of the starting solution was 0.0168. The catalyst was driedby evaporation and then calcined in air for one hour at about 370° C.The silver content, as calculated from the amount of silver nitratetaken up by the catalyst, was about 0.055 weight percent of thecatalyst. This catalyst will be referred to as Catalyst B.

Still another catalyst was prepared by immersing at room temperature47.2 grams of Catalyst A in 25 milliliters of water containing 0.0372grams of silver nitrate. The catalyst pills were swirled for about 3minutes and then the excess liquid decanted. The catalyst was dried andcalcined as was done in preparing Catalyst B. This catalyst is denotedherein as Catalyst B. By assuming that the catalyst retained the samefraction of silver from the silver nitrate solution as Catalyst A did,Catalyst C can be calculated to contain about 0.028 weight percentsilver.

EXAMPLE II Comparative Hydrogenation Reactions

Runs were made using the catalysts of Example I to determine theirselectivity to hydrogenate acetylene to ethylene. 20 mL portions ofcatalyst were placed in an 0.5 inch I.D. stainless steel reactor mountedvertically in an electrically-heated temperature-controlled tubefurnace. The space above and below the catalyst was filled with glassbeads. A 3/16" coaxial thermowell in the reactor contained a travelingthermocouple to measure catalyst temperature. Feedstock from an ethanecracking furnace passed downflow through the reactor. The composition ofthe feedstock for these runs is shown in Table I.

                  TABLE I                                                         ______________________________________                                        Compound      Conc., Mole %                                                   ______________________________________                                        H.sub.2       24.1                                                            CO            0.025                                                           CH.sub.4      11.5                                                            C.sub.2 H.sub.2                                                                             0.27                                                            C.sub.2 H.sub.4                                                                             40.5                                                            C.sub.2 H.sub.6                                                                             22.9                                                            C.sub.3 H.sub.6                                                                             0.70                                                            C.sub.3 H.sub.8                                                                             0.02                                                            ______________________________________                                    

The procedure followed in making runs was to purge and pressurize thereactor to 200 psig, the pressure used in all runs. After the desiredtemperature had been obtained, feedstock was introduced at about 2,600GHSV. Reactor effluent passed through 300 mL glass sample bombs and,when desired, bombs were closed and removed for GC Analysis using two1/8"×6' columns in series that contained Chromosorb 102 and Poropak T.

A number of successive runs were made with each catalyst usingincrementally higher temperatures. Plots were made of the ratio ofethylene to ethane in the reactor effluent samples taken at the variousreaction temperatures. The results are shown in FIG. 1. The curves showthat the increase in ethane production with increased temperature ismuch less dramatic for Catalysts B and C than for control Catalyst A.

Another way of illustrating the superiority of Catalysts B and C is tocompare the temperature spread between that which provides substantialelimination of acetylene and that which provides an arbitrarily selectedlevel of ethane. The "X" marks on the respective curves notes thetemperature at which acetylene was no longer detected (i.e. less than 5ppm). The value of 1.685 for a molar ratio of ethane to ethylene wasselected since that is a value in the area where runaway is exhibitedwith Catalyst A. This comparison is shown in Table II wherein .sup.Δ Tis the difference between the temperature at which the acetylene couldno longer be detected and the temperature at which the ethylene toethane ratio decreased to 1.685.

                  TABLE II                                                        ______________________________________                                        Catalyst       Ag, Wt.%  .sup.Δ T, °F.                           ______________________________________                                        A              0         12                                                   B              0.055     38                                                   C              0.028     18                                                   ______________________________________                                    

These results show that when the weight ratio of silver to palladium isless than 2 to 1 there is little improvement in .sup.Δ T. The resultsobtained with Catalyst B, however, shows that larger levels of silver doprovide a significant improvement in the .sup.Δ T.

What is claimed is:
 1. A catalyst for the selective hydrogenation ofacetylene consisting essentially of particles of alpha aluminacontaining metallic components consisting essentially of palladium andsilver wherein the palladium is about 0.01 to about 0.025 weight percentof the catalyst, the weight percent silver is at least twice that of thepalladium, the silver is distributed throughout said catalyst particles,and substantially all of the palladium is concentrated in an area within300 microns of the exterior surface of at least 90 percent of thecatalyst particles.
 2. A catalyst according to claim 1 wherein thedimensions of the catalyst particles are in the range of about 2 toabout 6 millimeters.
 3. A catalyst according to claim 2 wherein theweight ratio of silver to palladium is no greater than about
 10. 4. Acatalyst according to claim 2 wherein the weight ratio of silver topalladium is in the range of about 2 to about
 6. 5. A catalyst accordingto claim 4 containing about 0.02 weight percent palladium.
 6. A catalystaccording to claim 5 wherein said alpha alumina has surface area in therange of about 3 to about 7 square meters per gram, pore volume of about0.24 to about 0.34 cubic centimeters per gram, and a mean pore radius inthe range of about 685 to about 2,270 Angstrom units.
 7. A catalystaccording to claim 4 wherein said alpha alumina has surface area in therange of about 3 to about 7 square meters per gram, pore volume of about0.24 to about 0.34 cubic centimeters per gram, and a mean pore radius inthe range of about 685 to about 2,270 Angstrom units.
 8. A catalystaccording to claim 7 wherein said catalyst is prepared by impregnatingalumina particles with a solution of palladium chloride acidified withhydrochloric acid, then mixing the particles with an amount of anaqueous solution of silver nitrate in excess of the pore volume of thealumina.
 9. A catalyst according to claim 1 wherein said catalyst isprepared by impregnating alumina particles with a solution of palladiumchloride acidified with hydrochloric acid, then mixing the particleswith an amount of an aqueous solution of silver nitrate in excess of thepore volume of the alumina.